About This Project

Success Story: Legacy Mod30ML Boiler Controls Upgraded to Micro 2 with ICONICS GENESIS64 SCADA

Customer Overview

For more than 20 years, M&M Mars relied on Micromod Mod30ML controllers to operate its critical boiler systems. As the legacy platform reached end of life and replacement parts became increasingly difficult to obtain, the customer partnered with Micromod Automation & Controls to modernize its control system while preserving the proven boiler control strategy operators had trusted for decades.

The project included migrating the existing Mod30ML controllers to the Micromod Micro 2 Controller platform and implementing a new ICONICS GENESIS64 SCADA system, providing a modern automation solution with enhanced monitoring, alarm management, historical trending, and long-term lifecycle support.

The Challenge

Although the existing Mod30ML controllers had delivered more than two decades of reliable performance, hardware obsolescence and limited product support made modernization essential.

The customer required a solution that would:

• Replace legacy Mod30ML controllers with a modern, fully supported platform.
• Implement a new ICONICS GENESIS64 SCADA system.
• Preserve the existing boiler control strategy and operator familiarity.
• Complete the project with minimal disruption to ongoing plant operations.

Because the boilers supported critical manufacturing processes, maintaining continuous operation throughout the migration was a key project requirement. In addition plant couldn’t experience any production system downtime.

The Micromod Solution

Leveraging a partnership spanning more than 20 years, Micromod Automation & Controls delivered a complete turnkey modernization solution that included controller migration, SCADA implementation, engineering, startup, and commissioning.

Project scope included:

• Migration from legacy Mod30ML controllers to the Micromod Micro 2 Controller
• Engineering and configuration of the new control system
• Installation and commissioning of an ICONICS GENESIS64 SCADA platform
• Integration of all Micro 2 controllers into the new SCADA system
• Development of custom operator graphics, alarms, historical trending, and reporting
• Startup, testing, documentation, and operator support

Throughout the project, Micromod engineers worked closely with plant personnel to coordinate installation activities around operational requirements, allowing the modernization to be completed with minimal downtime during plants outage period.

The Results

The project successfully modernized the facility’s boiler control system while maintaining operational continuity.

By combining the Micro 2 Controller with an ICONICS GENESIS64 SCADA system, the customer gained a fully supported automation platform that improves operational visibility while extending the life of its critical boiler infrastructure.

Project Benefits

• Successful migration from Mod30ML controllers to the Micromod Micro 2 platform
• Modern ICONICS GENESIS64 SCADA system with centralized monitoring and control
• Improved alarm management and real-time process visibility
• Historical data collection and process trending
• Elimination of end-of-life hardware risks
• Minimal disruption to plant operations during implementation
• Scalable platform ready for future expansion
• Complete engineering, commissioning, and lifecycle support from Micromod

Customer Testimonial

“I would like to thank you and your team for successfully completing the upgrade of our MicroMod boiler controllers and the implementation of our new SCADA system at our facility.

Throughout the project, MicroMod demonstrated a high level of professionalism, technical expertise, and commitment to customer service. Their installation team worked efficiently while remaining flexible around our operational requirements, which was critical to maintaining continuity within our facility during the upgrade process.

In addition to the quality of the installation, their technical support was extremely responsive and helpful throughout the project. Communication was clear and proactive from start to finish. All schedules and planned activities were thoroughly conveyed prior to the commencement of work, allowing us to properly coordinate operations and minimize disruptions.

The project documentation provided was organized, detailed, and easy to follow, which greatly assisted both operations and maintenance personnel during startup and transition.

Based on our experience, I would confidently recommend MicroMod to any organization seeking boiler controls, SCADA integration, or related automation services. Their professionalism, technical knowledge, and customer-focused approach made this project a success.” 

Ready to Modernize Your Legacy Control System?

Whether you’re operating Mod30ML, MODCELL, Siemens 353/352 or other legacy Micromod or competitive platforms , Micromod Automation & Controls provides complete modernization solutions—from controller migration to turnkey SCADA implementation.

Our engineering team specializes in upgrading legacy industrial control systems with the Micro 2 Controller, integrating leading SCADA platforms such as ICONICS GENESIS64, and delivering projects with minimal downtime, maximum reliability, and long-term lifecycle support. Contact us today to discuss your modernization project.